Programmable distal tilt position of end effector for powered surgical devices

ABSTRACT

A surgical device includes a handle assembly having a controller and a motor. The surgical device also includes an adapter assembly having: a tubular housing having a proximal end portion configured to couple to the handle assembly and a distal end portion; and an actuation assembly configured to couple to the motor. The surgical further includes a reload configured to couple to the distal end portion of the adapter assembly; and an anvil assembly including an anvil head pivotally coupled to an anvil shaft, the anvil assembly configured to couple to the actuation assembly and the reload. The controller of the surgical device is configured to control the motor to actuate the actuation assembly to move the anvil assembly in a distal direction for a distance based on a dimension of one of the reload or the anvil head, thereby pivoting the anvil head relative to the anvil shaft while maintaining engagement of the anvil assembly to the reload.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 62/800,836 filed Feb. 4, 2019, the entire disclosure of which is incorporated by reference herein.

BACKGROUND 1. Technical Field

The present disclosure relates to surgical devices. More specifically, the present disclosure relates to handheld electromechanical surgical systems for performing surgical procedures with differently sized end effectors.

2. Background of Related Art

One type of surgical device is a circular clamping, cutting and stapling device. Such a device may be employed in a surgical procedure to reattach rectum portions that were previously transected, or similar procedures. Conventional circular clamping, cutting, and stapling devices include a pistol or linear grip-styled structure having an elongated shaft extending therefrom and a staple cartridge supported on the distal end of the elongated shaft. In this instance, a physician may insert the loading unit portion of the circular stapling device into a rectum of a patient and maneuver the device up the colonic tract of the patient toward the transected rectum portions. The loading unit includes a cartridge assembly having a plurality of staples. Along the proximal portion of the transected colon, an anvil assembly can be purse stringed therein. Alternatively, if desired, the anvil portion can be inserted into the colon through an incision proximal to the transected colon. The anvil and cartridge assemblies are approximated toward one another and staples are ejected from the cartridge assembly toward the anvil assembly thereby forming the staples in tissue to affect an end-to-end anastomosis, and an annular knife is fired to core a portion of the clamped tissue portions. After the end-to-end anastomosis has been effected, the circular stapling device is removed from the surgical site.

A number of surgical device manufacturers have also developed proprietary powered drive systems for operating and/or manipulating the end effectors. The powered drive systems may include a powered handle assembly, which may be reusable, and a disposable end effector that is removably connected to the powered handle assembly.

Many of the existing end effectors for use with existing powered surgical devices and/or handle assemblies are driven by a linear driving force. For example, end effectors for performing endo-gastrointestinal anastomosis procedures, end-to-end anastomosis procedures and transverse anastomosis procedures, are actuated by a linear driving force. As such, these end effectors are not compatible with surgical devices and/or handle assemblies that use rotary motion.

Some of the end effectors for use with powered surgical devices are of different sized. As such the powered surgical devices interface and actuate the end effectors based on their size. Accordingly, there is a need for powered surgical devices that are programmed to operate with various end effectors taking into consideration the size and other physical attributes of the end effectors.

SUMMARY

The present disclosure provides a powered surgical device for use with an annular stapler reload and a corresponding anvil assembly. During use the anvil is approximated toward the reload to compress and form staples through the tissue. After the procedure is completed the surgical device is extracted from the patient and the anvil assembly is moved away from the reload. The present disclosure provides for a controlled extraction process by moving the anvil assembly distally for a predetermined distance such that an anvil head of the anvil assembly is tilted while the anvil assembly is still engaged to the reload, e.g., via interfacing splines on an anvil shaft and the reload. This ensures that the surgical device can be manipulated without dislodging the anvil assembly from the reload.

According to one embodiment of the present disclosure, a surgical device includes a handle assembly having a controller and a motor. The surgical device also includes an adapter assembly having: a tubular housing having a proximal end portion configured to couple to the handle assembly and a distal end portion; and an actuation assembly configured to couple to the motor. The surgical device further includes a reload configured to couple to the distal end portion of the adapter assembly; and an anvil assembly including an anvil head pivotally coupled to an anvil shaft, the anvil assembly configured to couple to the actuation assembly and the reload. The controller of the surgical device is configured to control the motor to actuate the actuation assembly to move the anvil assembly in a distal direction for a distance based on a dimension of one of the reload or the anvil head, thereby pivoting the anvil head relative to the anvil shaft while maintaining engagement of the anvil assembly to the reload.

According to one aspect of the above embodiment, the anvil assembly includes a plurality of first splines disposed on the anvil shaft and the reload includes a plurality of second splines, such that upon coupling of the anvil assembly to the reload, the plurality of first splines interface with the plurality of second splines.

According to another aspect of the above embodiment, the controller includes a memory storing a plurality of distance values. The reload includes a storage device storing a dimension value of one of the reload or the anvil head. The controller is further configured to access the storage device to read the dimension value. The controller is also configured to select one distance value from the plurality of distance values based on the dimension value and to control the motor based on the selected distance value. The distance value is equal to a radius of the anvil head.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present disclosure are described herein with reference to the accompanying drawings, wherein:

FIG. 1 is a perspective view of a handheld surgical device, an adapter assembly, an end effector having a reload and an anvil assembly according to an embodiment of the present disclosure;

FIG. 2 is a perspective view illustrating a connection of the adapter assembly and the handle assembly of FIG. 1 according to an embodiment of the present disclosure;

FIG. 3 is perspective view of internal components of the handle assembly according to an embodiment of the present disclosure;

FIG. 4 is a perspective view of the adapter assembly of FIG. 1 without the reload according to an embodiment of the present disclosure;

FIG. 5 is a side, cross-sectional view, of the reload of FIG. 1 according to an embodiment of the present disclosure;

FIG. 6A is a perspective view of the distal end portion of the adapter assembly according to an embodiment of the present disclosure;

FIG. 6B is a cross-sectional view of the distal end portion of the adapter assembly according to an embodiment of the present disclosure;

FIG. 7 is a front, perspective view of an anvil assembly according to the present disclosure;

FIG. 8 is a rear, perspective view of the anvil assembly of FIG. 5;

FIG. 9 is a perspective view, with parts separated, of the anvil assembly of FIG. 5;

FIG. 10 is a longitudinal, cross-sectional view, illustrating the reload of FIG. 5 aligned with and separated from the distal end portion of the adapter assembly of FIG. 1;

FIG. 11 is a side view of the distal end portion of the adapter assembly with the reload and a first anvil assembly in a tilted configuration according to an embodiment of the present disclosure; and

FIG. 12 is a side view of the distal end portion of the adapter assembly with the reload and a second anvil assembly in a tilted configuration according to an embodiment of the present disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS

Embodiments of the present disclosure are now described in detail with reference to the drawings in which like reference numerals designate identical or corresponding elements in each of the several views. As used herein, the term “clinician” refers to a doctor, a nurse or any other care provider and may include support personnel. Throughout this description, the term “proximal” will refer to the portion of the device or component thereof that is closer to the clinician and the term “distal” will refer to the portion of the device or component thereof that is farther from the clinician. Additionally, in the drawings and in the description that follows, terms such as front, rear, upper, lower, top, bottom, and similar directional terms are used simply for convenience of description and are not intended to limit the disclosure. In the following description, well-known functions or constructions are not described in detail to avoid obscuring the present disclosure in unnecessary detail.

The present disclosure relates to powered surgical devices operable with annular reloads and corresponding annular anvil assemblies. The anvil assembly includes an anvil head that is pivotable relative to an anvil shaft. This allows the anvil assembly to move from a tilted configuration during navigation of the anvil assembly within the patient and a deployed configuration in which the anvil assembly is used to clamp tissue between the reload and form staples in the tissue. The reload includes a storage device storing one or more data values describing the reload, such as dimensions (e.g., diameter). The storage device is accessible by the surgical device, which utilizes the data values to determine a distance for moving the anvil assembly during extraction. In particular, the surgical device stores a plurality of distance values in its memory and selects an appropriate distance value based on the data value from the storage device. This ensures that the surgical device moves the anvil assembly for the selected distance, which is predetermined to ensure that the anvil assembly is transitioned to a tilted configuration while being engaged to the reload.

With reference to FIG. 1, a powered surgical device 10 includes a handle assembly 20, which is configured for selective connection with an adapter assembly 30, which in turn, is configured for selective connection with an end effector, such as an annular reload 40. The handle assembly 20 includes a handle housing 22 having a lower housing portion 24, an intermediate housing portion 26 extending from and/or supported on a portion of the lower housing portion 24, and an upper housing portion 28 extending from and/or supported on a portion of the intermediate housing portion 26. As shown in FIG. 2, a distal portion of the upper housing portion 28 defines a nose or connecting portion 28 a that is configured to accept a proximal end portion 30 b of the adapter assembly 30.

With reference to FIG. 3, the handle assembly 20 includes one or more motors 36 which are coupled to a battery 37. The handle assembly 20 also includes a main controller 38 for operating the motors 36 and other electronic components of the handle assembly 20, the adapter assembly 30, and the reload 40. The main controller 38 main include any suitable logic controller (e.g., FPGA) and a memory storing software instructions executable by the logic controller to operate the motors 36 as well as other components of the surgical device 10. The memory of the main controller 38 may also store various data in addition to software instructions. The motors 36 are coupled to corresponding drive shafts 39 (FIG. 2), which are configured to engage sockets 33 on the proximal end portion 30 b, such that rotation of the drive shafts 39 is imparted on the sockets 33. The actuation assembly 52 (FIG. 6B) is coupled to a respective socket 33. The actuation assembly 52 is configured to transfer rotational motion of the sockets 33 into linear motion and to actuate the reload 40 (FIG. 1) along with the anvil assembly 58.

With reference to FIG. 4, the adapter assembly 30 includes a tubular housing 30 a that extends between a proximal end portion 30 b that is configured for operable connection to the connecting portion 28 a of the handle assembly 20 and an opposite, distal end portion 30 c that is configured for operable connection to the reload 40. In this manner, the adapter assembly 30 is configured to convert a rotational motion provided by the handle assembly 20 into axial translation useful for advancing/retracting a trocar member 50 slidably disposed within the distal end portion 30 c of the adapter assembly 30 (FIG. 5) for firing staples of the reload 40.

With reference to FIG. 2, the connecting portion 28 a includes an electrical receptacle 29 having a plurality of electrical contacts 31, which are in electrical communication with electronic (e.g., main controller 38) and electrical components (e.g., battery 37) of the handle assembly 20. The adapter assembly 30 includes a counterpart electrical connector 32 supported within the proximal end portion 30 b that is configured to engage the electrical receptacle 29. The electrical connector 32 also includes a plurality of electrical contacts 34 that engage and electrically connect to their counterpart electrical contacts 31. Electrical connector 32 is of the adapter assembly 30.

With reference to FIG. 4, the trocar member 50 is slidably disposed within the tubular housing 30 a of the adapter assembly 30 and extends past the distal end portion 30 c thereof. In this manner, the trocar member 50 is configured for axial translation, which in turn, causes a corresponding axial translation of an anvil assembly 58 (FIG. 1) of the reload 40 to fire the staples (not shown) disposed therein. The trocar member 50 includes a proximal end which is coupled to the tubular housing 30 a of the adapter assembly 30. A distal end portion of the trocar member 50 is configured to selectively engage the anvil assembly 58 of the reload 40 (FIG. 4). In this manner, when the anvil assembly 58 is connected to the trocar member 50, as will be described in detail hereinbelow, axial translation of the trocar member 50 in the first direction results in an opening of the anvil assembly 58 relative to the reload 40, and axial translation of the trocar member 50 in a second, opposite direction, results in a closing of the anvil assembly 58 relative to the reload 40.

As illustrated in FIGS. 1 and 5, the reload 40 is configured for operable connection to adapter assembly 30 and is configured to fire and form an annular array of surgical staples, and to sever a ring of tissue. The reload 40 includes a housing 42 having a proximal end portion 42 a and a distal end portion 42 b and a staple cartridge 44 fixedly secured to the distal end portion 42 b of the housing 42. The proximal end portion 42 a of the housing 42 is configured for selective connection to the distal end portion 30 c of the adapter assembly 30 and includes a means for ensuring the reload 40 is radially aligned or clocked relative to the adapter assembly 30.

With reference to FIG. 5, the housing 42 of the reload 40 includes an outer cylindrical portion 42 c and an inner cylindrical portion 42 d. The outer cylindrical portion 42 c and the inner cylindrical portion 42 d of the reload 40 are coaxial and define a recess 46. The recess 46 of the reload 40 includes a plurality of longitudinally extending ridges or splines 48 projecting from an inner surface thereof which is configured to radially align the anvil assembly 58 relative to the reload 40 during a stapling procedure.

The reload 40 also includes a storage device 41 may be any non-volatile storage medium (e.g., EEPROM) that is configured to store any data pertaining to the reload 40, including but not limited to, usage count, identification information, model number, serial number, staple size, stroke length, maximum actuation force, minimum actuation force, factory calibration data, and the like. In embodiments, the data may be encrypted and is only decryptable by the main controller 38 having appropriate keys. The data may also be used to authenticate the reload 40. The storage device 41 may be configured in read only or read/write modes, allowing the main controller 38 to read as well as write data onto the storage device 41.

Load sensing assembly 66 is electrically connected to electrical connector 32 via a wiring harness. As shown in FIGS. 6A and 6B, an actuation assembly 52, which is coupled to the trocar member 50, extends through the load sensing assembly 66. The load sensing assembly 66 provides strain measurements imparted on the adapter assembly 30 during movement of the trocar member 50 when coupled to the anvil assembly 58 during clamping, stapling, cutting, and other mechanical actuations. The load sensing assembly 66 is disposed between a support block 54 and a connector sleeve 56. During operation of the surgical device 10, namely, clamping, stapling, and cutting, load sensing assembly 66 is elastically deformed (similar to a support beam) in proportion to the forces applied to the support block 54 and the connector sleeve 56. A change in a baseline of the measurement signal is indicative of the forces being imparted on the support block 54 and the connector sleeve 56, which are generally descriptive of the forces encountered during clamping, stapling, and cutting.

Referring now to FIGS. 7-10, an anvil assembly 58 is provided and is configured for selective connection to trocar member 50 of adapter assembly 30 and for clamping, stapling, and cutting tissue in cooperation with reload 40. Anvil assembly 58 includes a head assembly 112 and a center rod assembly 114. As shown in FIG. 9, the head assembly 112 includes a post 116, a housing 118, a cutting ring 122, a cutting ring cover 123, an anvil plate 124, a spacer 121, a cam latch 126, and a retainer member 127. Post 116 is centrally positioned within housing 118.

The anvil plate 124 is supported in an outer annular recess of housing 118 and includes a plurality of staple pockets 130 formed therein and configured to receive and form staples. Cutting ring 122 includes a central opening which is positioned about post 116 within an inner annular recess of housing 118 between post 116 and outer annular recess. Cutting ring 122 may be formed from any thermoplastic material, such as polyethylene. Cutting ring cover 123 is secured to an outwardly facing or proximal surface of cutting ring 122.

Retainer member 127 is positioned in the inner annular recess between cutting ring 122 and a back wall of housing 118. Retainer member 127 is annular and includes a plurality of deformable tabs which engage a rear surface of cutting ring 122. Retainer member 127 prevents cutting ring 122 from moving or being pushed into the inner annular recess of housing 118 until a predetermined force sufficient to deform the tabs has been applied to cutting ring 122. When the predetermined force is reached, e.g., during cutting of tissue, cutting ring 122 is urged into the inner annular recess 136 and compresses the retainer members.

With reference to FIG. 9, anvil center rod assembly 114 includes a center rod 152, a plunger 154 and a plunger spring 156. A first end of center rod 152 includes a pair of arms 119 which define a cavity 119 a. A pivot pin 162 is provided to pivotally secure post 116 to center rod 152 such that anvil head assembly 112 is pivotally mounted to anvil center rod assembly 114.

Cam latch 126 is pivotally mounted within a transverse slot of post 116 of housing 118 and about pivot pin 162. Cam latch 126 has an outer cam profile which permits plunger 154 to move forward as cam latch 126 rotates in a distal direction, and permits plunger 154 to be retracted as cam latch rotates in a proximal direction.

Plunger 154 is slidably positioned in a bore formed in the first end of center rod 152. Plunger 154 includes an engagement finger which is offset from the pivot axis of anvil head assembly 112 and biased into engagement with an edge of cam latch 126. Engagement of the finger of plunger 154 with the edge of cam latch 126 presses a leading portion of the edge of cam latch 126 against an inner periphery of cutting ring 122 to urge anvil head assembly 112 to an operative or non-tilted configuration on center rod 152.

Anvil head assembly 112 may be tilted relative to anvil center rod assembly 114 in a pre-fired tilted configuration. Tilting of anvil head assembly 112 relative to anvil center rod assembly 114 causes the body portion of cam latch 126 to engage a finger 166 of plunger 154. As cam latch 126 rotates with the tilting of anvil head assembly 112, plunger 154 is retracted with the bore of anvil center rod assembly 114, thereby compressing spring 156. In this manner, finger 166 of plunger 154 is distally biased against the body portion of cam latch 126.

With reference to FIGS. 8 and 9, a second end of center rod 152 includes a bore 180 defined by a plurality of flexible arms 182. The proximal end of each of the flexible arms 182 includes an internal shoulder dimensioned to releasably engage a shoulder of trocar member 50 of adapter assembly 30 to secure anvil assembly 58 to adapter assembly 30 as shown in FIG. 10. A plurality of splines 186 are formed about center rod 152. Splines 186 align the anvil assembly 58 with the reload 40 by engaging the splines 48 of the staple cartridge 44.

For a detailed description of an exemplary powered surgical stapler including an adapter assembly and a reload, reference may be made to commonly owned U.S. Patent Application Publication No. 2016/0310134 to Contini et al., titled “Handheld Electromechanical Surgical System,” filed Apr. 12, 2016, incorporated in its entirety by reference hereinabove.

The anvil assembly 58 along with the reload 40 are used to staple and subsequently cut tissue, such as during anastomosis procedures. After the stapling and cutting sequences are complete, the user begins an unclamping sequence to release the anvil assembly 58 from the trocar member 50, e.g., by pressing on a control button on the handle assembly 20. The trocar member 50 is automatically extended distally, thereby moving the anvil assembly 58 away from the reload 40 and unclamping the tissue to a preset anvil tilt distance. The unclamping sequence may be illustrated on a display screen 47 (FIG. 3). In particular, an unclamping animation shows the anvil assembly 58 moving distally and the head assembly 112 being tilted. In addition, the display screen 47 may also show a lock icon to show that the anvil assembly 58 is secured to the trocar member 50. Once the anvil assembly 58 is moved away from reload 40 to its tilt distance, the display screen 47 shows the anvil assembly 58 in the extended state with the head assembly 112 in the tilted state. This indicates that the user may remove the adapter assembly 30 from the patient.

The adapter assembly 30 may be used with a variety of differently sized reloads 40. In embodiments, the reloads 40 may have a diameter from about 20 millimeters (mm) to about 40 mm. The reloads 40 may be chosen based on the thickness of the organ being resected. Additionally, the anvil assemblies 58 correspond in size to the reloads 40 being used in the procedure such that the staples of the reload 40 contact the staple pockets 130 of the anvil assembly 58. Due to the size difference of different anvil assemblies 58 the surgical device 10 advances the anvil assembly 58 to a preset anvil tilt distance based on the dimensions of the anvil assembly 58. Since the dimensions of the anvil assembly 58, such as its diameter and/or radius, correspond to the dimensions of the reload 40, the surgical device 10 obtains the dimensions data from the storage device 41. Thus, rather than moving all of the anvil assemblies 58 to the same anvil tilt distance, the surgical device 10 moves the anvil assemblies 58 to a predetermined tilt distance based on the dimensions of the reload 40. This ensures the splines 186 of the anvil assembly 58 continue to engage the splines 48 of the staple cartridge 44.

With reference to FIGS. 11 and 12, the anvil assembly 158 is illustrated in a tilted configuration. FIG. 11 illustrates a smaller reload 40 (e.g., about 21 mm) whereas FIG. 12 illustrates a larger reload 40 (e.g., about 33 mm). Each of the anvil assemblies 158 is extended to a predetermined distance that corresponds to the size of the anvil assembly 158, namely its diameter and/or radius. As shown in FIGS. 11 and 12, the anvil assembly 158 of FIG. 11 is extended for a distance a and the anvil assembly 158 of FIG. 12 is extended for a distance b, based on the respective radii r₁ and r₂ of the anvil assemblies 158.

The main controller 38 of the surgical device 10 is configured to access dimensions data stored on the storage device 41 of the reload 40. The main controller 38 also stores a plurality of tilt distances in its memory. The main controller 38 is configured to select one tilt distance from the plurality of tilt distances based on the dimensions of the reload 40 and correspondingly the anvil assembly 58 as read from the storage device 41. The main controller 38 then operates the actuation assembly 52 to move the anvil assembly 58 to the selected tilt distance until the anvil head assembly 112 is tilted, allowing for extraction of the surgical device 10.

By remaining engaged to the splines 48 of the staple cartridge 44, the anvil assembly 58 is prevented from rotation in response to rotation of the surgical device 10, such as during twisting of the surgical device 10 by the clinician to pull through the anastomosis. Being able to twist the surgical device 10 allows for the anvil assembly 58 to be pulled through the anastomosis in potential snagging situations. Conversely, when the anvil assembly 58 is unsecured, it is free to spin and may remain snagged in the same position regardless of the twisting or maneuvering of the surgical device 10. Ensuring that the anvil assembly 58 remains secured may be beneficial in bariatric procedures as the tissues and locations that the anvil assemblies 58 are maneuvered in tend to move with the reload 40 rather than allowing the anvil assembly 58 to slide through the anastomosis. In these situations, twisting of the surgical device 10 allows for easier removal due to the anvil assembly 58 being engaged with the reload 40 due to the tailored anvil tilt distance that is programmed for each of the different reload sizes. Another benefit is the tailored distance shortens time required for operating the surgical device 10.

It will be understood that various modifications may be made to the embodiments of the presently disclosed adapter assemblies. Therefore, the above description should not be construed as limiting, but merely as exemplifications of embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the present disclosure. 

What is claimed is:
 1. A surgical device including: a handle assembly including a controller and a motor; an adapter assembly including: a tubular housing having a proximal end portion configured to couple to the handle assembly and a distal end portion; and an actuation assembly configured to couple to the motor; a reload configured to couple to the distal end portion of the adapter assembly; and an anvil assembly including an anvil head pivotally coupled to an anvil shaft, the anvil assembly configured to couple to the actuation assembly and the reload, wherein the controller is configured to control the motor to actuate the actuation assembly to move the anvil assembly in a distal direction for a distance based on a dimension of one of the reload or the anvil head, thereby pivoting the anvil head relative to the anvil shaft.
 2. The surgical device according to claim 1, wherein the anvil assembly includes a plurality of first splines disposed on the anvil shaft and the reload includes a plurality of second splines.
 3. The surgical device according to claim 2, wherein upon coupling of the anvil assembly to the reload, the plurality of first splines interface with the plurality of second splines.
 4. The surgical device according to claim 1, wherein the controller includes a memory storing a plurality of distance values.
 5. The surgical device according to claim 4, wherein the reload includes a storage device storing a dimension value of one of the reload or the anvil head.
 6. The surgical device according to claim 5, wherein the controller is configured to access the storage device to read the dimension value.
 7. The surgical device according to claim 6, wherein the controller is configured to select one distance value from the plurality of distance values based on the dimension value.
 8. The surgical device according to claim 7, wherein the controller is configured to control the motor based on the selected distance value.
 9. The surgical device according to claim 7, wherein the distance value is equal to a radius of the anvil head. 